Slide rolling process for the generation of bevel gears

Abstract

Generating cutting processes for producing bevel gears and employing a single rotary disc cutter ( 36 ) wherein a portion of the generating cutting process effectively includes a reduction ( 38 ) of the workpiece roll angle ( 40 ) during generating thereby reducing or eliminating cutting action on the clearance side ( 42 ) of the rotary disc cutter.

What is claimed is: 
     
       1. A method of rough manufacturing a gear tooth on a workpiece, said manufacturing being carried out by a cutting tool having a plurality of cutting blades with each of said cutting blades having a cutting edge and a clearance edge, said method comprising:
 rotating said cutting tool, 
 bringing the rotating cutting tool and said workpiece into contact with one another, 
 rotating said workpiece, 
 moving said cutting tool relative to said workpiece to define a generating roll for generating said gear tooth, 
 wherein said rotating of said workpiece comprises rotating the workpiece in a first direction from a start roll position to an end roll position, and wherein said workpiece is rotated at a first rate of rotation less than a theoretical rate of rotation beginning at said start roll position and ending prior to said end roll position, 
 or, 
 wherein said moving of said cutting tool comprises moving the cutting tool in a first direction from a start roll position to an end roll position, and wherein said cutting tool is moved at a first rate of movement greater than a theoretical rate of movement beginning at said start roll position and ending prior to said end roll position. 
 
     
     
       2. The method of  claim 1  wherein a center roll position is located between said start roll position and said end roll position and wherein said first rate of workpiece rotation occurs between said start roll position and said center roll position. 
     
     
       3. The method of  claim 2  wherein said first rate of workpiece rotation ends prior to said center roll position. 
     
     
       4. The method of  claim 2  wherein subsequent to said first rate of rotation, said workpiece is rotated at said theoretical rate of rotation to said end roll position. 
     
     
       5. The method of  claim 1  wherein no cutting action is performed by said clearance edge. 
     
     
       6. The method of  claim 1  wherein subsequent to reaching said end roll position, said workpiece is rotated in an opposite direction while in contact with said cutting tool to provide a finished profile on said gear tooth. 
     
     
       7. The method of  claim 6  wherein the workpiece rotation in said opposite direction is carried out at said theoretical rate. 
     
     
       8. The method of  claim 6  wherein prior to rotating said workpiece in said opposite direction, a set-over motion of the cutting tool relative to the workpiece is performed. 
     
     
       9. The method of  claim 1  wherein said first rate of rotation is constant. 
     
     
       10. The method of  claim 1  wherein said first rate of rotation is variable. 
     
     
       11. The method of  claim 1  wherein said cutting tool is a rotary disc cutter. 
     
     
       12. The method of  claim 11  wherein said rotary disc cutter includes cutting blades oriented at a dish angle. 
     
     
       13. The method of  claim 1  wherein said cutting tool is a face cutter.